International Journal of Emerging Technologies and Engineering (IJETE)

Volume 1 Issue 7, August 2014, ISSN 2348 8050

Structural Performance of Concrete by Partial Replacement of

Cement with Hypo Sludge (paper waste)
Abdullah shahbaz khan1, Ram panth2, Gagan Krishna R.R3, Suresh G. Patil4
1

PG student, 2Assistant professor, 3Associate professor, 4Professor,

Srinivas School of Engineering, Suratkal Mangalore, 2Guru Nanak Dev Engineering College Bidar, 3Srinivas School of Engineering,
Suratkal Mangalore, 4PDAC Gulbarga

ABSTRACT
The rapid increase in construction activities
leads to active shortage of conventional construction
materials such as cement, fine aggregate and coarse
aggregate. Researches were searching for cheaper
materials that can be used as substitute for these
materials. In the world of concrete many artificial
pozzolans are found by research such as fly ash, blast
furnace slag, silica fume, rice husk ash, etc other than
this the recent studies has show that the waste from
paper industries has pazzolanic property termed as hypo
sludge hypo sludge contains low calcium and minimum
amount of silica. Hypo sludge behaves like cement
because of silica and magnesium properties. The silica
and magnesium improve the setting of concrete. By
utilizing hypo sludge the strength will be increased and
also cost reduction in the concrete is achieved. The
present dissertation work is directed towards developing
low cost concrete from paper industry waste.
Dissertation work is carried out with M20 & M30 grade
concrete with W/c ratio of 0.55 & 0.45 respectively as a
control specimen and hypo sludge is replaced in
different percentages such as 10%, 20%, and 30% by
weight of cement. Cubes of 150mm x 150mm size,
Cylinders of 100 mm dia and 200mm height, and prisms
of 100 mm x 100mm x 500mm are casted for
conventional concrete and RPH (Replacement of hypo
sludge by weight of cement) test specimen respectively.
Test was conducted to study the mechanical properties
of concrete, such as compressive strength, split tensile
strength and flexural strength. The curing period should
be 3, 7 and 28 days.
Key words : Hypo Sludge, M20 and M30 grade concrete,
cubes, cylinders, prisms.
I.

INTRODUCTION
Concrete, is most widely used man made
construction material and is the largest production of all

the materials used in construction industry. Concrete is

basically made of cementitious materials which have to
properly bind themselves together, as well as with other
materials to form a solid mass. Concrete or mortar is
made up of cement, water and aggregates (Coarse and
Fine Aggregate) and sometimes with necessary
admixtures. Concrete has attained the status of a major
building material in all the branches of modern
construction. It is difficult to point out another material
of construction which is as variable as concrete.
Concrete is the best material of choice where strength,
durability, impermeability, fire resistance and absorption
resistance are required. Compressive strength is
considered as an index to assess the overall quality of
concrete and it is generally assumed that an
improvement in the compressive strength results in
improvement of all other properties. Hence strength
investigations are generally centered on compressive
strength. Even though concrete mixes are proportioned
on the basis of achieving the desired compressive
strength at the specified age, flexural strength often play
a vital role in concrete making. Hypo sludge (paper
industry waste) has a tremendous potential in this
context and it is well documented that the use of hypo
sludge in concrete results in a significant improvement is
the rheological prosperities.
Hypo sludge is a recent arrival among
cementitions materials. It was originally introduced as
artificial pozzolana while producing paper the various
wastes are comes out from the various processes in
paper industries. From the preliminary waste named as
hypo sludge due to its low calcium is taken out for our
project to replace the cement utilization in concrete.
Paper making industries generally produces a
large amount of solid waste. Paper fibers can be
recycled only a limited number of time before they
become too short or weak to make high quality paper.
From paper manufacturing process three types of sludge
are obtained namely lime sludge (Hypo sludge), ETP
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International Journal of Emerging Technologies and Engineering (IJETE)

Volume 1 Issue 7, August 2014, ISSN 2348 8050

sludge and De-Inking sludge. In our project we have

utilized lime sludge as a replacement for cement. Lime
sludge (Hypo sludge is a material obtained from the
chemical recovery process of paper production. Hypo
sludge is available abundantly worldwide, but its usage
to date is very limited. Each Indian mill produces an
average 40 over-dry tones of sludge per day. The
specific gravity hypo sludge is generally 2.82 but it is
very slightly higher when the silica content is lower.
This value can be compared with the specific gravity of
Portland cement which is 3.15.
The particles of hypo sludge are extremely fine,
most of them having a diameter ranging between 0.04
and 0.3 m, the median diameter is typically below
0.1m. such a fine material as hypo sludge has a very
low bulk density 200 to 350 kg/m3 handling this light
powder is difficult.
Chemical reactions involved in partially replaced
concrete
1. Primary Hydration
Cement + Water C-S-H (gel) + Ca (OH)2
2. Secondary Hydration
Here hypo sludge acts as a pozzolana
Ca (OH)2+ Pozzolana C-S-H (gel)
Increase in amount of C-S-H gel increase the
compressive strength but only up to a certain extent.
Benefits of Hypo Sludge
Hypo sludge improves the properties of fresh
and harden concrete.
Hypo sludge reduces degradation and bleeding.
Hypo sludge improves the durability of concrete.
Hypo sludge improves the setting of concrete
due to presence of silica and magnesium.
Environmental friendly.
Light weight compare to conventional concrete.
Hypo sludge is the cheaper substitute to OPC.
Limitations of Hypo Sludge
Availability
Handling problem

II.

and strength with the conventional concrete(10). Over 300

million tones of industrial wastes are being produced per
annum by chemical and agricultural process in India.
These materials pose problems of disposal and health
hazards. The waste like phosphogypsum, flurogypsum
and red mud contain obnoxious impurities which
adversely affect the strength and other properties of
building material based on them. Out of several wastes
being produced at present, the use of phosphor gypsum,
flurogypsum, lime sludge, hypo sludge, red mud and
mine tailing is of paramount significance to protect the
environment(10).
Paper fibers can be recycled only a limited
number of times before they become too short or weak
to make high quality paper. It means that the broken low
quality paper fibers are separated out to become waste
sludge. All the inks, dyes, coatings, pigments, stapes
and Stickies (tape, plastic films etc) are also washed
off the recycled fibers to join the waste solids(02).This
paper mill sludge consumes a large percentage of local
land fill space for each and every year. Worse yet, some
of the wastes are land spread on crop land as a disposal
technique raising concerns about trace contaminants
building up in soil or running off into area lakes and
streams.
Some companies turn their sludge in incinerators
contributing to our serious air pollution problems. To
reduce disposal and pollution problems emanating from
these industrial wastes. It is most essential to develop
profitable building materials from them. Keeping this in
view investigations were under taken to produce low
cost concrete by blending various ratios of cement with
hypo sludge(03). In Trondheim, the source factory
produces 800 tons each year, with much more for the
entire(04). Waste paper sludge obtained from a paper
factory in Trondheim, Norway, It has bulk density
460kg/m3 specific gravity 2.6, ash content of 94% and a
pH value of 11.4. The material is essentially composed
of amorphous silicates and aluminates, mainly gehlenite
(2CaO.Al2O3SiO2)
and
melilite
(8CaO3Al2O3MgO5SiO2); which are responsible for a
pozzolanic reaction(08).

LITRETURE REVIEW

III.

The use of paper-mill pulp in concrete

formulations was investigated as an alternative to
landfill disposal. The cement has been replaced by waste
paper sludge accordingly in the range of 10%, 20%, 30%
by weight for M20 and M30 mix. By using adequate
amount of the waste paper pulp and water, concrete
mixtures were produced and compared in terms of slump

MATERIALS AND PROPERTIES

The materials used in research are:

1. Portland cement (53 grade)
2. Fine aggregate (4.75 mm down)
3. Coarse aggregate (20 mm down)
4. Hypo Sludge
5. Water
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International Journal of Emerging Technologies and Engineering (IJETE)

Volume 1 Issue 7, August 2014, ISSN 2348 8050

Cement:
Cement is a fine, grey powder. It is mixed with
water and materials such as sand, pozzolanas to make
mortar and concrete. The cement and water forms a
paste that binds the other materials together. In this work
ordinary Portland cement of 53 grade conforming to IS:
12269-1987 has been used and tested for physical and
chemical properties.
Fine Aggregate
In the investigation fine aggregate is natural
sand from local market is used, confirming grading zone
II as per IS: 383-1997. The physical properties of fine
aggregate like specific gravity, gradation and fineness
modulus are tested in accordance with IS :2386.
Coarse Aggregate
Coarse aggregate crushed granite of 20 mm
down size has been used as coarse aggregate. The
physical properties of coarse aggregate like specific
gravity, gradation and fineness modulus are tested in
accordance with IS: 2386.
Hypo Sludge
Hypo sludge is also known as paper industry
waste. It is the byproduct of the paper waste. This hypo
sludge contains low calcium and minimum amount of
silica. Hypo sludge behaves like cement because of silica
and magnesium properties.
Hypo sludge may be used as part replacement of
cement. It is usually used in proportion of percent of
cement content of the mix. Hypo sludge obtained from
Gemini Graphics (P) Ltd., Sikenpur village district
Bidar.
Table 3.1: Chemical Properties of Hypo Sludge
Percent in
Sl.No.
Constituent
Hypo Sludge
(%)
1.
Moisture
2.97
Magnesium
2.
4.64
Oxide (MgO)
Calcium Oxide
3.
15.12
(CaO)
4.
R2O3
9.31
5.
Silica (SiO2)
3.09
6.
Acid Insoluble
13.88

impurities such as oil, alkali, acid, etc, in general, the

water, which is fit for drinking should be used for
making concrete.

IV.

MIX DESIGN

A mix M20 and M30 grade was designed as per IS

10262:2009 and the same was used to prepare the test
samples. The design mix proportion is shown in blow
table.
Table 4.1: Concrete Mix Design Proportion for 1 m3 of
concrete
Sl
n
o
1.
2.
3.
4.
5.
6.
7.
8.

Typ
e of
mix
CV
CM20
S1M20
S2M20
S3M20
CV
CM30
K1M30
K2M30
K3M30

w/c
rati
o

Ceme
nt

Fine
aggrega
te

Corse
aggrega
te

Hypo
Sludg
e

0.5
0

1.0

1.96

2.85

0.9

1.96

2.85

0.10

0.8

1.96

2.85

0.20

0.7

1.96

2.85

0.30

1.0

1.29

2.43

0.9

1.29

2.43

0.10

0.8

1.29

2.43

0.20

0.7

1.29

2.43

0.30

0.5
0
0.5
0
0.5
0
0.4
0
0.4
0
0.4
0
0.4
0

CVC-conventional concrete,
S1, S2, S3 for M20 grade concrete with different Hypo
Sludge percentage 10%, 20%, 30% respectively.
K1, K2, K3 for M30 grade concrete with different Hypo
Sludge percentage 10%, 20%, 30% respectively.

V.

Water
The water, which is used for making concrete
and for curing, should be clean and free from harmful

EXPERIMENTAL PROGRAMME

The quantity of cement, fine and coarse

aggregates, hypo sludge and water each batch of
proportion is prepared as mentioned in mix design. Then
the mixing process is carried out.
Tests for Fresh Properties of concrete
Workability tests included the determination of
slump cone test.
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International Journal of Emerging Technologies and Engineering (IJETE)

Volume 1 Issue 7, August 2014, ISSN 2348 8050

Table:6.2 Results of Slump Cone Test M20 and M30

Mix
M20 Slump
M30 Slump
designation cone (mm)
cone (mm)

Casting of Moulds
Once the workability tests are over, concrete is
filled into the moulds (cubes, cylinders and beams) and
compaction process has to be carried out. Then casted
moulds are de-moulded and the specimens are kept
inside the water for curing till test day (3, 7 and 28
days).
Mechanical Properties Tests
To determine the hardened properties of
concrete standard tests were carried out at standard ages
(3,7days and 28 days of curing) i.e., compression test on
cubes for compressive strength (three cubes of
150x150x150mm size), split tensile test on cylinders for
tensile strength (three cylinders of 100mm dia with
200mm height) and flexural test on beams for flexural
strength (three beams 500x100x100mm) of concrete for
each grade with different mix proportions of hypo
sludge.

RESULTS AND DISCUSSION

Setting time for cement and hypo sludge

Table:6.1 Setting Time for Cement and Hypo sludge
Sl.
No.

Ingredients

Cement + 0%
Hypo sludge

30

600

Cement + 10%
Hypo sludge

33

596

Cement + 20%
Hypo sludge

35

598

Cement + 30%
Hypo sludge

37

595

Cement + 40%
Hypo sludge

39

Cement + 50%
Hypo sludge

Initial
time (min)

40

50

50

M1

48

46

M2

45

42

M3

41

38

SLUMP VALUES
SLUMP VALUES IN mm

VI.

CVC

Final time
(min)

60
50
40
30
20
10
0

M20
M30
cvc

M1

M2

M3

DIFFERENT MIX PROPORTIONS

Fig.6.1 Slump values for various mixes (M20, M30)

Table:6.3 Mechanical Properties of Concrete with
Different mix Proportions
Mixs Compressive strength
Split
Flexural
(N/mm2)
tensile
strength
strength (N/mm2)
(N/mm2)
3 days
7
28
28 days
28 days
days days
2.80
1.92
CVC1 11.93 19.59 27.1

593

590

Slump Cone Test results

Workability tests, slump cone tests conducted on
fresh concrete and the results are shown in table .

S1

16.49

28.74 34.79

3.8

2.43

S2

14.38

23.29 29.18

2.93

1.93

S3

10.37

18.17

23.7

2.55

1.54

CVC2

17.79

24.98 39.40

4.02

2.62

K1

21.74

33.47 45.17

5.51

3.06

K2

18.17

27.94 40.17

3.79

2.57

K3

13.37

20.43 31.43

3.26

2.33
178

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International Journal of Emerging Technologies and Engineering (IJETE)

Volume 1 Issue 7, August 2014, ISSN 2348 8050

Here CVC1, CVC2 Conventional Concrete for M20,

M30 Grade concrete Respectively
S1, S2 and S3 are 10%, 20% and 30% RPH for M20,
Grade concrete Respectively
K1, K2 and K3 are 10%, 20% and 30% RPH for
M30, Grade concrete Respectively

4
3.5
3
2.5
2
28 days

1.5
40

35

0.5
0

30

CVC1

25
3 days

20

7 days
15

S1

S2

S3

Fig.6.4 Split tensile strength results for 28 days of curing

for M20 Grade Concrete
6

28 days

10

3
CVC1

S1

S2

28 days

S3
2

Fig.6.2 Compressive strength results for different curing

period for M20 Grade Concrete

1
0

50

CVC2

K1

K2

K3

45

Fig.6.5 Split tensile strength results for 28 days of curing

for M30 Grade Concrete

40
35
30
25
20

3 days

7 days

2.5

28 days

15

10
1.5

28 days

1
CVC2

K1

K2

K3

0.5

Fig.6.3 Compressive strength results for different curing

period for M30 Grade Concrete

0
CVC1

S1

S2

S3

Fig.6.6 Flexural strength results for 28 days of curing for

M30 Grade Concrete
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International Journal of Emerging Technologies and Engineering (IJETE)

Volume 1 Issue 7, August 2014, ISSN 2348 8050

replacement it is slightly more or we can say it as

equivalent but with 30% its start decreasing in strength.
The prisms which contains 30% of RPH breaks
earlier with the influence of two point loading condition
where as 10%, 20%, shows more deflection and carries
higher load but CVC prisms break earlier without
showing mutch cracks.

3.5
3
2.5
2
1.5

28 days

REFERENCES

0.5
0
CVC2

K1

K2

K3

Fig.6.7 Flexural strength results for 28 days of curing for

M30 Grade Concrete
By this table and graphs results shows that there
is an increase in compressive strength, split tensile
strength and flexural strength with 10%, 20%
replacement of cement with hypo sludge and it decreases
with 30% replacement.

VII.

CONCLUSION

1. COMPRESSIVE STRENGTH
Compressive strength of concrete with various
mixes with different curing periods which are 3, 7, 28
days by partial replacement of cement with hypo sludge
that is 0%, 10%, 20%, 30% which are noted as CVC1,
S1, S2, S3 and CVC2, K1,K2,K3.
The compressive strength increases as the curing
period increasing for M20, M30 grade concrete,
compressive strength of CVC and 20% are
approximately same but it increase with 10%
replacement and finally it starts decreasing in strength
with 30% replacement.
2. SPLIT TENSILE STRENGTH
It is observed that in split tensile strength of M20
and M30 grade concrete. The strength of concrete has
increased with 10% replacement of hypo sludge with
cement as compare to conventional concrete and with
20% replacement it is slightly more or we can say it as
equivalent but with 30% its start decreasing in strength.
3. FLEXURAL STRENGTH
It is observed that in flexural strength of M20 and
M30 grade concrete the strength of concrete has increased
with 10% replacement of hypo sludge with cement as
compare to conventional concrete and with 20%

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International Journal of Emerging Technologies and Engineering (IJETE)

Volume 1 Issue 7, August 2014, ISSN 2348 8050

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